Non-Penetrating Roofing System and Methods of Installation

ABSTRACT

Devices, systems, and methods for installing a new roof that does not require penetration of the outward facing roof surface, conjoined panels secured with a securement bar provide an easily installed, durable, and non-penetrating surface covering for roofs.

BACKGROUND OF THE INVENTION 1) Field of the Invention

The present disclosure relates to devices and methods for installing anew roof that does not require penetration of the outward facing roofsurface, conjoined panels secured with a securement bar provide aneasily installed, durable, and non-penetrating surface covering forroofs.

2) Description of Related Art

Roof installation commonly requires very tedious installation steps, aswell as requires puncturing the roof of the building hundreds, if notthousands, of times to secure roof panels or shingles to a structure'sroof. Typically, nails or screws are used to install the roofing alongeach rib in the panel with screws beginning about seven (7) inches fromthe bottom of the roof and placing subsequent screws/nails from eighteen(18) to twenty four (24) inches apart along the vertical run. Attemptsto prevent leaks, such as placing a washer under the screw or nail headhave been attempted to prevent the screw or nail from creating an accessfor foreign objects, insects and/or water to leak into the structure.However, overtightening or failing to secure the nail or screw canrender this attempt useless while also perforating the roof structure.Further, some installations use a line of sealant, such as silicone,between roof panels along the underside of the short edge of the nextpanel so that the sealant will spread and adhere, creating a seal.

Roofing screws are responsible for the majority of leaks on metal roofs.Metal roofing screws seal water out by compressing a rubber washer atthe base of the screw head. When the screw is driven into the metalroofing panel the rubber washer forms a “gasket” between the roofingpanel and the screw head. It sounds simple enough but several things cango wrong with screw installation such as: under driving screws; overdriving screws; driving screws at the wrong angle; and screws thatmissed the framing member. Even if the screws are installed correctly,leaks may then occur due to failure of the gasket at the screw head. Hotsummers followed by hard cold winters are unkind to the washers, whichdegrade and lose their seal. Moreover, it is can be very difficultvisually to distinguish a screw that is leaking from one that is not.

What is needed is an improved roofing system that does away with themultitude of punctures created by ordinary roofing systems. Accordingly,it is an object of the present invention to provide a punctureless,non-penetrating roof installation system and methods of installing same.

Citation or identification of any document in this application is not anadmission that such a document is available as prior art to the presentdisclosure.

SUMMARY OF THE INVENTION

The above objectives are accomplished according to the presentdisclosure by providing in one aspect a non-penetrating roof panelsystem. The system may include at least one roof panel, at least oneretaining bar, the at least one roof panel configured to define at leastone first hollow chamber and at least one second hollow chamber, the atleast one roof panel configured such that the at least one retaining barextends through a length of the at least one roof panel via insertioninto the at least one first hollow chamber; and wherein the at least oneroof panel is configured so that no part of any roof contacting surfaceof the at least one roof panel penetrates into a surface of a roof uponwhich the at least one roof panel is affixed. Further, the at least oneroof panel may be formed from at least one metal. Still yet, the atleast one roof panel may configured to define at least one panelstructure. Still again, the at least one panel structure may include atleast one mound, at least one ridge, at least one trapezoidal shape,and/or at least one interconnecting region. Further yet, the at leastone roof panel may affixed to at least one second roof panel. Moreover,the at least one retaining bar may be malleable. Still again, the atleast one first hollow chamber and the at least one second hollowchamber may be configured such that the at least one first hollowchamber of the at least one roof panel will engage and at leastpartially enclose the at least one second hollow chamber of at least onesecond roof panel. Further again, the at least one roof panel may extendfrom at least one panel fascia edge to at least one roof edge of theroof. Still moreover, the at least one retaining bar may be configuredto define a fascia engaging end and a roof ridge engaging end and thefascia engaging end and/or the roof engaging end comprise a formedbending point. Further still again, the at least one retaining bar maybe held in place with respect to the at least one roof panel withoutscrews, nails or other fixtures penetrating the at least one roof panelto hold the at least one retaining bar in place on the roof.

In a further aspect, a method for installing an unpenetrated roofsurface is provided. The method may include applying a first panel to aroof surface wherein the first panel defines a first panel first hollowchamber and a first panel second hollow chamber, applying a second panelto the roof surface wherein the second panel defines a second panelfirst hollow chamber and a second panel second hollow chamber, engagingthe second panel to the first panel via complimentary engagement of afirst joining edge of the first panel to a second joining edge of thesecond panel such that the second panel first hollow chamber at leastpartially encloses the first panel second hollow chamber to form a firstpanel/second panel hollow cavity, inserting a retaining rod within thefirst panel/second panel hollow cavity formed by the first panel engagedwith the second panel, and fastening the retaining rod to at least aroof fascia or roof ridge of the roof surface. Further, a third panelmay be configured to define a third panel first hollow chamber and athird panel second hollow chamber, wherein the second panel is affixedto the third panel via complimentary engagement of a first joining edgeof the second panel to a second joining edge of the third panel suchthat the third panel first hollow chamber at least partially enclosesthe second panel second hollow chamber to form a second panel/thirdpanel hollow cavity. Further, a second retaining rod may be insertedwithin the second panel/third panel hollow cavity formed by the secondpanel engaged with the third panel. Moreover, the method may includejoining a series of panels to one another to substantially cover anentirety of the roof surface. Still further, the first panel may beformed from at least one metal. Again, the first panel may define atleast one panel structure. Still yet, the at least one panel structuremay be configured to include at least one mound, at least one ridge, atleast one trapezoidal shape, and/or at least one interconnecting region.Even further, the retaining rod may be malleable. Still yet again, theretaining bar may define a fascia engaging end and a roof ridge engagingend and the fascia engaging end and/or the roof engaging end comprise aformed bending point. Still further yet, the at least one retaining barmay be configured to be held in place without screws, nails or otherfixtures penetrating any roof panel or the roof to hold the at least oneretaining rod in place on the roof.

These and other aspects, objects, features, and advantages of theexample embodiments will become apparent to those having ordinary skillin the art upon consideration of the following detailed description ofexample embodiments.

BRIEF DESCRIPTION OF THE DRAWINGS

An understanding of the features and advantages of the presentdisclosure will be obtained by reference to the following detaileddescription that sets forth illustrative embodiments, in which theprinciples of the disclosure may be utilized, and the accompanyingdrawings of which:

FIG. 1 shows one embodiment of a roof panel of the current disclosure.

FIG. 2 shows a front profile of one embodiment of a roof panel of thecurrent disclosure.

FIG. 3 shows one embodiment of a retaining bar of the currentdisclosure.

FIG. 4 shows two panels of the current disclosure partially engaged withone another.

FIG. 5 shows multiple panels and retaining bars used to place a roof ona structure.

FIG. 6 shows one embodiment of a method for creating anunpunctured/nonpenetrated roof surface per the current disclosure.

It will be understood by those skilled in the art that one or moreaspects of this invention can meet certain objectives, while one or moreother aspects can meet certain other objectives. Each objective may notapply equally, in all its respects, to every aspect of this invention.As such, the preceding objects can be viewed in the alternative withrespect to any one aspect of this invention. These and other objects andfeatures of the invention will become more fully apparent when thefollowing detailed description is read in conjunction with theaccompanying figures and examples. However, it is to be understood thatboth the foregoing summary of the invention and the following detaileddescription are of a preferred embodiment and not restrictive of theinvention or other alternate embodiments of the invention. Inparticular, while the invention is described herein with reference to anumber of specific embodiments, it will be appreciated that thedescription is illustrative of the invention and is not constructed aslimiting of the invention. Various modifications and applications mayoccur to those who are skilled in the art, without departing from thespirit and the scope of the invention, as described by the appendedclaims. Likewise, other objects, features, benefits and advantages ofthe present invention will be apparent from this summary and certainembodiments described below, and will be readily apparent to thoseskilled in the art. Such objects, features, benefits and advantages willbe apparent from the above in conjunction with the accompanyingexamples, data, figures and all reasonable inferences to be drawntherefrom, alone or with consideration of the references incorporatedherein.

DETAILED DESCRIPTION OF A PREFERRED EMBODIMENT

With reference to the drawings, the invention will now be described inmore detail. Unless defined otherwise, all technical and scientificterms used herein have the same meaning as commonly understood to one ofordinary skill in the art to which the presently disclosed subjectmatter belongs. Although any methods, devices, and materials similar orequivalent to those described herein can be used in the practice ortesting of the presently disclosed subject matter, representativemethods, devices, and materials are herein described.

Unless specifically stated, terms and phrases used in this document, andvariations thereof, unless otherwise expressly stated, should beconstrued as open ended as opposed to limiting. Likewise, a group ofitems linked with the conjunction “and” should not be read as requiringthat each and every one of those items be present in the grouping, butrather should be read as “and/or” unless expressly stated otherwise.Similarly, a group of items linked with the conjunction “or” should notbe read as requiring mutual exclusivity among that group, but rathershould also be read as “and/or” unless expressly stated otherwise.

Furthermore, although items, elements or components of the disclosuremay be described or claimed in the singular, the plural is contemplatedto be within the scope thereof unless limitation to the singular isexplicitly stated. The presence of broadening words and phrases such as“one or more,” “at least,” “but not limited to” or other like phrases insome instances shall not be read to mean that the narrower case isintended or required in instances where such broadening phrases may beabsent.

Throughout this application, various embodiments of this invention maybe presented in a range format. It should be understood that thedescription in range format is merely for convenience and brevity andshould not be construed as an inflexible limitation on the scope of theinvention. Accordingly, the description of a range should be consideredto have specifically disclosed all the possible subranges as well asindividual numerical values within that range. For example, descriptionof a range such as from 1 to 6 should be considered to have specificallydisclosed subranges such as from 1 to 3, from 1 to 4, from 1 to 5, from2 to 4, from 2 to 6, from 3 to 6 etc., as well as individual numberswithin that range, for example, 1, 2, 3, 4, 5, and 6. This appliesregardless of the breadth of the range.

Whenever a numerical range is indicated herein, it is meant to includeany cited numeral (fractional or integral) within the indicated range.The phrases “ranging/ranges between” a first indicate number and asecond indicate number and “ranging/ranges from” a first indicate number“to” a second indicate number are used herein inter-changeably and aremeant to include the first and second indicated numbers and all thefractional and integral numerals therebetween.

FIG. 1 shows a non-penetrating roof panel 100 of the current disclosure.Panel 100 may come in a wide variation of shapes, styles and colors.Further, panel 100 may be made from a variety of metals, including butnot limited to copper, tin, or aluminum, steel, fiberglass, and/orpolymers. Panel 100 may also be comprised of plastics or synthetics toprovide lighter weight panels. FIG. 1 also shows retaining bar 102 thatextends through length 104 of panel 100 via panel first hollow chamber106. Panel 100 may be shaped along width 108 to form panel structures110 such as mounds, ridges, trapezoidal shapes, and interconnectingregions 112 that may be flat, curved, etc. Panel 100 also defines panelsecond hollow chamber 114. Retaining bar 102 may be made from steel,iron, aluminum, etc. Retaining bar 102 may be made from a steel bar. Forinstance, steel bars with various thicknesses and widths may be sized tobetter fit the roof being renovated.

FIG. 2 shows an end on front profile view of FIG. 1 . Roof contactingsurfaces 200 will remain unpenetrated during installation as retainingbar 102 runs the length 104 of panel 100. Thus, no portion of panel 100will penetrate, extend into, or otherwise pierce the roof surface, suchas being screwed into the roof, nailed, or otherwise affixed such that aportion of panel 100 would dig into, abrade, penetrate or otherwisebreak the plane of the roof surface. This maintains panel upper surface120 and panel lower surface 122 as unblemished wholes with no screws,nails, or other fixture mechanisms penetrating through either uppersurface 120 or lower surface 122 of panel 100. This creates anunperforated panel surface 124 that extends from panel fascia edge 126to panel roof ridge edge 128, which remedies the common leakage issuescause by employing fixtures that penetrate prior art roof panels. In afurther embodiment, retaining bar 102 may be formed such that fasciaengaging end 408 and roof ridge engaging end 410 may be malleable, suchas with a formed bending point 407 as known to those of the art orhinged in order to allow retaining bar 102 to be inserted through panelretaining bar orifice 318, see FIG. 3 , and then bent to engage thefascia and roof ridge in order to secure retaining bar 102 to the roofstructure, see FIG. 5 .

Panel 100 has a first joining edge 116 and second joining edge 118.These ends form a complimentary joint 300, see FIG. 3 showing two panelspartially engaged end to end, whereby first joining edge 116 at leastpartially overlaps and at least partially covers second joining edge118. While first joining edge 116 is shown forming first flange 300,second flange 302, third flange 304 and fourth flange 306, and secondjoining edge 118 is shown forming fifth flange 308, sixth flange 310 andseventh flange 312, the current disclosure is not so limited and more orless flanges are considered within this disclosure such as 8, 9, 10, 11,etc., further, while the flanges are shown with angular bends 314, thebends may be more rounded or more angled depending on the roofrequirements.

By placing first joining edge 116 over second joining edge 118,concurrent panels form panel joint 316. Panel joint 316 functions byengaging the various flanges to define panel retaining bar orifice 318.Orifice 318 contains retaining bar 102, not shown, and provides aweather/insect proof continuous joint that is not penetrated by screws,nails, etc. Here, retaining bar 102 lays atop and at least partiallyoverlaps first flange 300, which is then pressed into contact withinterconnecting region 112. As FIG. 3 shows, joining to panels createsretaining bar orifice 318 that defines a hollow cavity 320 that enclosesretaining bar 102. However, due to the “clasping” or male/femaleengagement of first joining edge 116 and second joining edge 118,clasping meaning that the panel ends engage and overlap such that thepanels at least partially enclose one another and give the appearance ofclasping hands or fingers, this enables two adjoining or concurrentpanels to be connected along the entirety of their length and affixed toa roof structure without requiring any penetration of panel uppersurface 122, panel lower surface 124, or any penetration of the roofstructure below. Even if water were to enter at Arrow A, which would beclosed in use due to the weight of bar 102, see FIG. 5 , the flangescreate a water tight barrier without requiring sealants, fixtures, etc.,to hold the panels in engagement with one another. Many angle variationsare possible for the joining edges, such as from 0 to 180 degrees andvariations within this range. The current disclosure system may becustomized to each roof being renovated/built.

FIG. 4 shows retaining bar 102. Bar 102 has first affixment end 400 andsecond affixment end 402. First affixment end 400 may attach to the rooffascia, not shown, while second affixment end 402 affixes to the roofridge, not shown. Retaining bar 102 may be affixed via attachmentorifices 404 via screws, nails, spikes, etc., as known to those of skillin the art. Thus, bar 102 extends along length of panel 104 from theroof fascia to the roof ridge forming a unitary, unpenetrated layer thatis held in place via the weight of bar 102 and affixment ends 400 and402. Therefore, retaining bar upper body 406 does not requirepenetration by screws, nails or other fixtures to hold it and panel 100into place on a roof structure. Many angle variations are possible forthe bar ends, such as from 0 to 180 degrees and variations within thisrange. The current disclosure system may be customized to each roofbeing renovated/built.

FIG. 5 shows first panel 500 joined to second panel 502 at first joint503, which in turn is joined to third panel 504 at second joint 505 withrestraining bars 102 affixed to the fascia 506 of roof 507 as well asroof ridge 508. As FIG. 5 illustrates, the current disclosure providesfor a roofing system that securely affixes panels 500, 502 and 504 toroof 507 without necessitating use of screws, nails, or other fixturesthrough any portion of panels 500, 502, 504, which in turn form anunpenetrated roof surface 124 with greater resistivity to leakage thancurrently available roofs. The dimensions of panels 500, 502, and 503are typically uniform to one another in use but may different sizesdepending on the surface being coated. In one embodiment, panels may becut to a length that spans the “run” of the roof from fascia to roofridge such that a single panel substantially covers the length of theroof while multiple panels are affixed to one another in order to coverthe width of the roof surface. Example panel sizes include, but are notlimited to, 24, 36, 48 inches, etc., and the current disclosure shouldnot be considered limited to a particular panel size. Further, differentsize panels may be simultaneously employed on the same roof, whennecessary.

The current disclosure also provides methods of installing anunpenetrated roof surface 600. FIG. 6 shows one example of aninstallation method of the current disclosure. At 602, a first panel isapplied to a roof surface. At 604, a second panel, with a retaining rod“nested” within panel second hollow chamber is placed beside the firstpanel. At step 606, the second panel is engaged to the first panel viacomplimentary engagement of a first joining edge of the first panel tothe second joining edge of the second panel. At step 608, the retainingbar is positioned to engage a portion of at least one flange of thefirst panel and to overlap at least a portion of an interconnectingregion of the second panel, overlap may mean the retaining bar is indirect contact with the interconnecting region or may lay atop a flangeover the interconnecting region. At step 610, the retaining bar isfastened to the roof fascia and roof ridge. At step 612, a third panelwith a nested retaining bar is placed beside the second panel. At step614, the third panel is engaged with the first joining edge of thesecond panel via the second joining edge of the third panel. At step616, the second retaining bar is positioned with respect to the thirdpanel and second panel as described at step 608. At step 616, the secondretaining bar is secured in place to the roof fascia and roof ridge. Atstep 620, steps 612-618 may be repeated with additional panels andretaining bars until the width of the roof is covered. At step 622, thelast panel may put in place as described previously or it may be sizedto end adjacent to the roof or with some portion extending beyond theroof edge.

In use, retaining bar 102 may require a metal bending too to shape ends400 and 402 to place them in position for fastening to the fascia boardat the roof edge and at the crown of the roof. Many roofs will vary inshape and will require some adjustment in shaping and bending retainingbar 102. If a ridge cap is available to cover panel 100, it may fastenover top of panel(s) 100 and fasten down without driving nails or screwsin panel(s) 100.

All patents, patent applications, published applications, andpublications, databases, websites and other published materials referredto throughout the entire disclosure herein, unless noted otherwise, areincorporated herein by reference in their entirety.

While the present subject matter has been described in detail withrespect to specific exemplary embodiments and methods thereof, it willbe appreciated that those skilled in the art, upon attaining anunderstanding of the foregoing may readily produce alterations to,variations of, and equivalents to such embodiments. Accordingly, thescope of the present disclosure is by way of example rather than by wayof limitation, and the subject disclosure does not preclude inclusion ofsuch modifications, variations and/or additions to the present subjectmatter as would be readily apparent to one of ordinary skill in the artusing the teachings disclosed herein.

What is claimed is:
 1. A non-penetrating roof panel system comprising:at least one roof panel; at least one retaining bar; the at least oneroof panel configured to define at least one first hollow chamber and atleast one second hollow chamber; the at least one roof panel configuredsuch that the at least one retaining bar extends through a length of theat least one roof panel via insertion into the at least one first hollowchamber; and wherein the at least one roof panel is configured so thatno part of any roof contacting surface of the at least one roof panelpenetrates into a surface of a roof upon which the at least one roofpanel is affixed.
 2. The non-penetrating roof panel system of claim 1,wherein the at least one roof panel is formed from at least one metal.3. The non-penetrating roof panel system of claim 1, wherein the atleast one roof panel is configured to define at least one panelstructure.
 4. The non-penetrating roof panel system of claim 1, whereinthe at least one panel structure comprises at least one mound, at leastone ridge, at least one trapezoidal shape, and/or at least oneinterconnecting region.
 5. The non-penetrating roof panel system ofclaim 1, wherein the at least one roof panel is affixed to at least onesecond roof panel.
 6. The non-penetrating roof panel system of claim 1,wherein the at least one retaining bar is malleable.
 7. Thenon-penetrating roof panel system of claim 1, wherein the at least onefirst hollow chamber and the at least one second hollow chamber areconfigured such that the at least one first hollow chamber of the atleast one roof panel will engage and at least partially enclose the atleast one second hollow chamber of at least one second roof panel. 8.The non-penetrating roof panel system of claim 1, wherein the at leastone roof panel extends from at least one panel fascia edge to at leastone roof edge of the roof.
 9. The non-penetrating roof panel system ofclaim 1, wherein the at least one retaining bar is configured to definea fascia engaging end and a roof ridge engaging end and the fasciaengaging end and/or the roof engaging end comprise a formed bendingpoint.
 10. The non-penetrating roof panel system of claim 1, wherein theat least one retaining bar is held in place with respect to the at leastone roof panel without screws, nails or other fixtures penetrating theat least one roof panel to hold the at least one retaining bar in placeon the roof.
 11. A method for installing an unpenetrated roof surfacecomprising: applying a first panel to a roof surface wherein the firstpanel defines a first panel first hollow chamber and a first panelsecond hollow chamber; applying a second panel to the roof surfacewherein the second panel defines a second panel first hollow chamber anda second panel second hollow chamber; engaging the second panel to thefirst panel via complimentary engagement of a first joining edge of thefirst panel to a second joining edge of the second panel such that thesecond panel first hollow chamber at least partially encloses the firstpanel second hollow chamber to form a first panel/second panel hollowcavity; inserting a retaining rod within the first panel/second panelhollow cavity formed by the first panel engaged with the second panel;and fastening the retaining rod to at least a roof fascia or roof ridgeof the roof surface.
 12. The method for installing an unpenetrated roofsurface of claim 11, further comprising a third panel configured todefine a third panel first hollow chamber and a third panel secondhollow chamber, wherein the second panel is affixed to the third panelvia complimentary engagement of a first joining edge of the second panelto a second joining edge of the third panel such that the third panelfirst hollow chamber at least partially encloses the second panel secondhollow chamber to form a second panel/third panel hollow cavity.
 13. Themethod for installing an unpenetrated roof surface of claim 12, furthercomprising inserting a second retaining rod within the secondpanel/third panel hollow cavity formed by the second panel engaged withthe third panel.
 14. The method for installing an unpenetrated roofsurface of claim 11, further comprising joining a series of panels toone another to substantially cover an entirety of the roof surface. 15.The method for installing an unpenetrated roof surface of claim 11,further comprising forming the first panel from at least one metal. 16.The method for installing an unpenetrated roof surface of claim 11,further comprising configuring the first panel to define at least onepanel structure.
 17. The method for installing an unpenetrated roofsurface of claim 16, further comprising configuring the at least onepanel structure to include at least one mound, at least one ridge, atleast one trapezoidal shape, and/or at least one interconnecting region.18. The method for installing an unpenetrated roof surface of claim 11,further comprising configuring the retaining rod to be malleable. 19.The method for installing an unpenetrated roof surface of claim 11,further comprising configuring the at least one retaining rod to definea fascia engaging end and a roof ridge engaging end and the fasciaengaging end and/or the roof engaging end comprise a formed bendingpoint.
 20. The method for installing an unpenetrated roof surface ofclaim 11, further comprising configuring the at least one retaining rodto be held in place without screws, nails or other fixtures penetratingany roof panel or the roof to hold the at least one retaining rod inplace on the roof.